Neighboring gate-all-around integrated circuit structures having disjoined epitaxial source or drain regions

ABSTRACT

Neighboring gate-all-around integrated circuit structures having disjoined epitaxial source or drain regions, and methods of fabricating neighboring gate-all-around integrated circuit structures having disjoined epitaxial source or drain regions, are described. For example, a structure includes first and second vertical arrangements of nanowires, the nanowires of the second vertical arrangement of nanowires having a horizontal width greater than a horizontal width of the nanowires of the first vertical arrangement of nanowires. First and second gate stacks are over the first and second vertical arrangements of nanowires, respectively. First epitaxial source or drain structures are at ends of the first vertical arrangement of nanowires, and second epitaxial source or drain structures are at ends of the second vertical arrangement of nanowires. An intervening dielectric structure is between neighboring ones of the first epitaxial source or drain structures and of the second epitaxial source or drain structures.

TECHNICAL FIELD

Embodiments of the disclosure are in the field of integrated circuitstructures and processing and, in particular, neighboringgate-all-around integrated circuit structures having disjoined epitaxialsource or drain regions, and methods of fabricating neighboringgate-all-around integrated circuit structures having disjoined epitaxialsource or drain regions.

BACKGROUND

For the past several decades, the scaling of features in integratedcircuits has been a driving force behind an ever-growing semiconductorindustry. Scaling to smaller and smaller features enables increaseddensities of functional units on the limited real estate ofsemiconductor chips. For example, shrinking transistor size allows forthe incorporation of an increased number of memory or logic devices on achip, lending to the fabrication of products with increased capacity.The drive for ever-more capacity, however, is not without issue. Thenecessity to optimize the performance of each device becomesincreasingly significant.

In the manufacture of integrated circuit devices, multi-gatetransistors, such as tri-gate transistors, have become more prevalent asdevice dimensions continue to scale down. In conventional processes,tri-gate transistors are generally fabricated on either bulk siliconsubstrates or silicon-on-insulator substrates. In some instances, bulksilicon substrates are preferred due to their lower cost and becausethey enable a less complicated tri-gate fabrication process. In anotheraspect, maintaining mobility improvement and short channel control asmicroelectronic device dimensions scale below the 10 nanometer (nm) nodeprovides a challenge in device fabrication. Nanowires used to fabricatedevices provide improved short channel control.

Scaling multi-gate and nanowire transistors has not been withoutconsequence, however. As the dimensions of these fundamental buildingblocks of microelectronic circuitry are reduced and as the sheer numberof fundamental building blocks fabricated in a given region isincreased, the constraints on the lithographic processes used to patternthese building blocks have become overwhelming. In particular, there maybe a trade-off between the smallest dimension of a feature patterned ina semiconductor stack (the critical dimension) and the spacing betweensuch features.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates cross-sectional views taken through nanowires andfins for a non-endcap architecture (left-hand side) versus aself-aligned gate endcap (SAGE) architecture (right-hand side), inaccordance with an embodiment of the present disclosure.

FIG. 2 illustrate cross-sectional views representing various operationsin a method of fabricating a self-aligned gate endcap (SAGE) structurewith gate-all-around devices, in accordance with an embodiment of thepresent disclosure.

FIGS. 3A-3C illustrate cross-sectional views representing variousoperations in a method of fabricating a self-aligned gate endcap (SAGE)structure with gate-all-around devices having epitaxial source or drainstructures, in accordance with an embodiment of the present disclosure.

FIGS. 4A-4E illustrate cross-sectional views representing variousoperations in a method of fabricating neighboring gate-all-aroundintegrated circuit structures having disjoined epitaxial source or drainregions, in accordance with an embodiment of the present disclosure.

FIG. 5A illustrates a three-dimensional cross-sectional view of ananowire-based integrated circuit structure, in accordance with anembodiment of the present disclosure.

FIG. 5B illustrates a cross-sectional source or drain view of thenanowire-based integrated circuit structure of FIG. 5A, as taken alongthe a-a′ axis, in accordance with an embodiment of the presentdisclosure.

FIG. 5C illustrates a cross-sectional channel view of the nanowire-basedintegrated circuit structure of FIG. 5A, as taken along the b-b′ axis,in accordance with an embodiment of the present disclosure.

FIGS. 6A-6E illustrate three-dimensional cross-sectional viewsrepresenting various operations in a method of fabricating a nanowireportion of a fin/nanowire structure, in accordance with an embodiment ofthe present disclosure.

FIG. 7 illustrates a computing device in accordance with oneimplementation of an embodiment of the disclosure.

FIG. 8 illustrates an interposer that includes one or more embodimentsof the disclosure.

DESCRIPTION OF THE EMBODIMENTS

Neighboring gate-all-around integrated circuit structures havingdisjoined epitaxial source or drain regions, and methods of fabricatingneighboring gate-all-around integrated circuit structures havingdisjoined epitaxial source or drain regions, are described. In thefollowing description, numerous specific details are set forth, such asspecific integration and material regimes, in order to provide athorough understanding of embodiments of the present disclosure. It willbe apparent to one skilled in the art that embodiments of the presentdisclosure may be practiced without these specific details. In otherinstances, well-known features, such as integrated circuit designlayouts, are not described in detail in order to not unnecessarilyobscure embodiments of the present disclosure. Furthermore, it is to beappreciated that the various embodiments shown in the Figures areillustrative representations and are not necessarily drawn to scale.

Certain terminology may also be used in the following description forthe purpose of reference only, and thus are not intended to be limiting.For example, terms such as “upper”, “lower”, “above”, and “below” referto directions in the drawings to which reference is made. Terms such as“front”, “back”, “rear”, and “side” describe the orientation and/orlocation of portions of the component within a consistent but arbitraryframe of reference which is made clear by reference to the text and theassociated drawings describing the component under discussion. Suchterminology may include the words specifically mentioned above,derivatives thereof, and words of similar import.

Embodiments described herein may be directed to front-end-of-line (FEOL)semiconductor processing and structures. FEOL is the first portion ofintegrated circuit (IC) fabrication where the individual devices (e.g.,transistors, capacitors, resistors, etc.) are patterned in thesemiconductor substrate or layer. FEOL generally covers everything up to(but not including) the deposition of metal interconnect layers.Following the last FEOL operation, the result is typically a wafer withisolated transistors (e.g., without any wires).

Embodiments described herein may be directed to back end of line (BEOL)semiconductor processing and structures. BEOL is the second portion ofIC fabrication where the individual devices (e.g., transistors,capacitors, resistors, etc.) are interconnected with wiring on thewafer, e.g., the metallization layer or layers. BEOL includes contacts,insulating layers (dielectrics), metal levels, and bonding sites forchip-to-package connections. In the BEOL part of the fabrication stagecontacts (pads), interconnect wires, vias and dielectric structures areformed. For modern IC processes, more than 10 metal layers may be addedin the BEOL.

Embodiments described below may be applicable to FEOL processing andstructures, BEOL processing and structures, or both FEOL and BEOLprocessing and structures. In particular, although an exemplaryprocessing scheme may be illustrated using a FEOL processing scenario,such approaches may also be applicable to BEOL processing. Likewise,although an exemplary processing scheme may be illustrated using a BEOLprocessing scenario, such approaches may also be applicable to FEOLprocessing.

One or more embodiments are directed to epitaxial region (EPI) splittingor separating or disjoining for multi-width (Wsi) ribbons havingas-formed merged EPI regions. One or more embodiments are directed toneighboring semiconductor structures or devices having that areotherwise not separated by self-aligned gate endcap (SAGE) structures(e.g., on a die not including SAGE, or in a portion of a die notincluding SAGE formation).

In a particular embodiment, a high temperature carbon hardmask (HTCHM)material is deposited on a merged or joined structure. A lithographicpattern is defined over an area that needs to be split or disjoined. Anetch process is performed to split select merged EPI region. The splitarea is backfilled with dielectric material, and the HTCHM is optionallyremoved to enable further processing. In one or more embodiments, mergedepitaxial regions are disjoined for gate-all-around structures, such asnano-ribbon/nano-wire technology.

Particular embodiments may be directed to integration of multiple width(multi-Wsi) nanowires and nanoribbons in a non-SAGE architecture, or inneighboring regions of a SAGE architecture that are not immediatelyseparated by a SAGE wall. In an embodiment, nanowires/nanoribbons areintegrated with multiple Wsi in a non-SAGE architecture or non-SAGEportion of a front end process flow. Such a process flow may involveintegration of nanowires and nanoribbons of different Wsi to providerobust functionality of next generation transistors with low power andhigh performance.

To provide context, balancing non-uniform epitaxial growth acrossintegrated circuit structures can be challenging. Embodiments describedherein may address unwanted merged epitaxial growth associated withgrowing source or drain structures on silicon (Si) regions havingdifferential nanoribbon/nanowire architectures. Epitaxial regions may beembedded (e.g., portions of nanowires removed and then source or drain(S/D) growth is performed) or formed by vertical merging (e.g.,epitaxial regions are formed around existing wires), as described ingreater detail below in association with FIGS. 6A-6E.

To provide further context, advantages of a self-aligned gate endcap(SAGE) architecture may include the enabling of higher layout densityand, in particular, scaling of diffusion to diffusion spacing. However,certain application may not involve the use of SAGE, or regions of astructure may not include SAGE walls, yet high density may still besought after. In such scenarios, undesirable merging of neighboringepitaxial regions may occur in high density locations.

To provide illustrative comparison, FIG. 1 illustrates cross-sectionalviews taken through nanowires and fins for a non-endcap architecture(left-hand side (a)) versus a self-aligned gate endcap (SAGE)architecture (right-hand side (b)), in accordance with an embodiment ofthe present disclosure.

Referring to the left-hand side (a) of FIG. 1, an integrated circuitstructure 100 includes a substrate 102 having fins 104 protrudingtherefrom by an amount 106 above an isolation structure 108 laterallysurrounding lower portions of the fins 104. Corresponding nanowires 105are over the fins 104. A gate structure may be formed over theintegrated circuit structure 100 to fabricate a device. However, breaksin such a gate structure may be accommodated for by increasing thespacing between fin 104/nanowire 105 pairs. Alternatively, withoutincreased spacing, merging of epitaxially grown source or drainstructures can occur, as described in greater detail below.

By contrast, referring to the right-hand side (b) of FIG. 1, anintegrated circuit structure 150 includes a substrate 152 having fins154 protruding therefrom by an amount 156 above an isolation structure158 laterally surrounding lower portions of the fins 104. Correspondingnanowires 155 are over the fins 154. Isolating SAGE walls 160 (which mayinclude a hardmask thereon, as depicted) are included within theisolation structure 158 and between adjacent fin 154/nanowire 155 pairs.The distance between an isolating SAGE wall 160 and a nearest fin154/nanowire 155 pair defines the gate endcap spacing 162. A gatestructure may be formed over the integrated circuit structure 150,between insolating SAGE walls to fabricate a device. Breaks in such agate structure are imposed by the isolating SAGE walls. Since theisolating SAGE walls 160 are self-aligned, restrictions fromconventional approaches can be minimized to enable more aggressivediffusion to diffusion spacing. Furthermore, since gate structuresinclude breaks at all locations, individual gate structure portions maybe layer connected by local interconnects formed over the isolating SAGEwalls 160. In an embodiment, as depicted, the SAGE walls 160 eachinclude a lower dielectric portion and a dielectric cap on the lowerdielectric portion.

A self-aligned gate endcap (SAGE) processing scheme involves theformation of gate/trench contact endcaps self-aligned to fins withoutrequiring an extra length to account for mask mis-registration. Thus,embodiments may be implemented to enable shrinking of transistor layoutarea. Embodiments described herein may involve the fabrication of gateendcap isolation structures, which may also be referred to as gatewalls, isolation gate walls or self-aligned gate endcap (SAGE) walls.Other embodiments, however, involve applications, or regions of a die orarchitecture that include neighboring structures that are not separatedby isolation gate walls or self-aligned gate endcap (SAGE) walls.

In an exemplary processing scheme for structures having SAGE wallsseparating neighboring devices, FIG. 2 illustrate cross-sectional viewsrepresenting various operations in a method of fabricating aself-aligned gate endcap (SAGE) structure with gate-all-around devices,in accordance with an embodiment of the present disclosure.

Referring to part (a) of FIG. 2, a starting structure includes ananowire patterning stack 204 above a substrate 202. A lithographicpatterning stack 206 is formed above the nanowire patterning stack 204.The nanowire patterning stack 204 includes alternating silicon germaniumlayers 210 and silicon layers 212. A protective mask 214 is between thenanowire patterning stack 204 and the lithographic patterning stack 206.In one embodiment, the lithographic patterning stack 206 is trilayermask composed of a topographic masking portion 220, an anti-reflectivecoating (ARC) layer 222, and a photoresist layer 224. In a particularsuch embodiment, the topographic masking portion 220 is a carbonhardmask (CHM) layer and the anti-reflective coating layer 222 is asilicon ARC layer.

Referring to part (b) of FIG. 2, the stack of part (a) islithographically patterned and then etched to provide an etchedstructure including a patterned substrate 202 and trenches 230.

Referring to part (c) of FIG. 2, the structure of part (b) has anisolation layer 240 and a SAGE material 242 formed in trenches 230. Thestructure is then planarized to leave patterned topographic maskinglayer 220′ as an exposed upper layer.

Referring to part (d) of FIG. 2, the isolation layer 240 is recessedbelow an upper surface of the patterned substrate 202, e.g., to define aprotruding fin portion and to provide a trench isolation structure 241beneath SAGE walls 242.

Referring to part (e) of FIG. 2, the silicon germanium layers 210 areremoved at least in the channel region to release silicon nanowires 212Aand 212B. Subsequent to the formation of the structure of part (e) ofFIG. 2, a gate stacks may be formed around nanowires 212B or 212A, overprotruding fins of substrate 202, and between SAGE walls 242. In oneembodiment, prior to formation of the gate stacks, the remaining portionof protective mask 214 is removed. In another embodiment, the remainingportion of protective mask 214 is retained as an insulating fin hat asan artifact of the processing scheme.

Referring again to part (e) of FIG. 2, it is to be appreciated that achannel view is depicted, with source or drain regions being locatinginto and out of the page. In an embodiment, the channel region includingnanowires 212B has a width less than the channel region includingnanowires 212A. Thus, in an embodiment, an integrated circuit structureincludes multiple width (multi-Wsi) nanowires. Although structures of212B and 212A may be differentiated as nanowires and nanoribbons,respectively, both such structures are typically referred to herein asnanowires. It is also to be appreciated that reference to or depictionof a fin/nanowire pair throughout may refer to a structure including afin and one or more overlying nanowires (e.g., two overlying nanowiresare shown in FIG. 2).

In an exemplary process flow for structures having SAGE walls separatingneighboring devices, a planarizing material is formed over structureshaving uneven epitaxial growth and a non-selective etch is used torecess the planarizing material and the structures having unevenepitaxial growth. For example, FIGS. 3A-3C illustrate cross-sectionalviews representing various operations in a method of fabricating aself-aligned gate endcap (SAGE) structure with gate-all-around deviceshaving epitaxial source or drain structures, in accordance with anembodiment of the present disclosure.

Referring to FIG. 3A, a method of fabricating an integrated circuitstructure 300 includes forming a first vertical arrangement of nanowires306 and a second vertical arrangement of nanowires 304 above a substrate302. The nanowires of the second vertical arrangement of nanowires 304have a horizontal width greater than a horizontal width of the nanowiresof the first vertical arrangement of nanowires 306 (e.g., nanowires 306may be referred to as nanowires, and nanowires 304 may be referred to asnanoribbons). A gate endcap isolation structure 308 is formed betweenthe first vertical arrangement of nanowires 306 and the second verticalarrangement of nanowires 304. First epitaxial source or drain structures312 are formed at ends of the first vertical arrangement of nanowires306 (only one end depicted in FIG. 3A). Second epitaxial source or drainstructures 310 are formed at ends of the second vertical arrangement ofnanowires 304 (only one end depicted in FIG. 3A).

In an embodiment, the second epitaxial source or drain structures 310have an uppermost surface above the uppermost surface of the gate endcapisolation structure 308, as is depicted in FIG. 3A. In one suchembodiment, the first epitaxial source or drain structures 312 have anuppermost surface below the uppermost surface of the gate endcapisolation structure 308, as is also depicted in FIG. 3A. In anembodiment, the first vertical arrangement of nanowires 306 is over afirst fin, and the second vertical arrangement of nanowires 304 is overa second fin, as exemplified in FIG. 2.

Referring to FIG. 3B, a planarizing material 314 is formed over thestructure of FIG. 3A. In one embodiment, the planarizing material 314 isa carbon hardmask material deposited by atomic layer deposition (ALD) orchemical vapor deposition (CVD) and then subjected to a chemicalmechanical planarization process. In another embodiment, the planarizingmaterial 314 is a flowable silicon oxide based material. In anembodiment, planarizing material 314 is flowable material and can beused to fill a narrow narrow trench. In some embodiment, the depositionleads to a relatively flat surface and, hence, an actual “planarization”operation may be optional. It is to be appreciated that a carbonhardmask may be used as a flowable material, however, a flowable oxidecan also be used as well.

Referring to FIG. 3C, the uppermost surface of the second epitaxialsource or drain structures 310 are recessed below the uppermost surfaceof the gate endcap isolation structure 308 to form integrated circuitstructure 350 having recessed second epitaxial source or drainstructures 310′ and recessed planarizing material 314′. In anembodiment, the recessing is performed using an etch process that is notselective between the planarizing material 314 and the second epitaxialsource or drain structures 310. The recessed planarizing material 314′may subsequently be removed to enable contact formation. In anembodiment, in the case that a selective etch is performed, a masking orinter-layer dielectric material is first recessed to prior to apre-epitaxial etch in order to recess masking or inter-layer dielectricmaterial separately.

Referring again to FIG. 3C, in an embodiment, as depicted, the recessingfurther involves recessing an uppermost surface of the first epitaxialsource or drain structures 312 to form recessed first epitaxial sourceor drain structures 312′. In an embodiment, the uppermost surfaces ofthe epitaxial source or drain structures are recessed below theuppermost surface of the gate endcap isolation structure 308 to inhibitshorting of devices due to conductive or semiconducting structuresprotruding above the gate endcap isolation structure 308.

By contrast, in an exemplary process flow for structures not having SAGEwalls separating neighboring devices, FIGS. 4A-4E illustratecross-sectional views representing various operations in a method offabricating neighboring gate-all-around integrated circuit structureshaving disjoined epitaxial source or drain regions, in accordance withan embodiment of the present disclosure.

Referring to FIG. 4A, a method of fabricating an integrated circuitstructure 400 includes forming a first vertical arrangement of nanowires406 and a second vertical arrangement of nanowires 404 above a substrate402. The nanowires of the second vertical arrangement of nanowires 404have a horizontal width greater than a horizontal width of the nanowiresof the first vertical arrangement of nanowires 406 (e.g., nanowires 406may be referred to as nanowires, and nanowires 404 may be referred to asnanoribbons). First epitaxial source or drain structures 412 are formedat ends of the first vertical arrangement of nanowires 406 (only one enddepicted in FIG. 3A). Second epitaxial source or drain structures 410are formed at ends of the second vertical arrangement of nanowires 404(only one end depicted in FIG. 3A). Ones of the second epitaxial sourceor drain structures 410 and corresponding ones of the first epitaxialsource or drain structures 412 have a merged region 413 there between.

Referring again to FIG. 4A, a hardmask 414, such as a carbon hardmask isformed over the second epitaxial source or drain structures 410 and thefirst epitaxial source or drain structures 412, and the merged region413 there between. Referring to FIG. 4B, hardmask 414 is used as afoundation together with a stack 420 to form a trilayer mask composed ofa topographic masking portion (hardmask 414), an anti-reflective coating(ARC) layer 422, and a photoresist layer 424 patterned to have anopening 426 therein. In a particular such embodiment, theanti-reflective coating layer 422 is a silicon ARC layer.

Referring to FIG. 4C, the pattern of the opening 426 is extended throughthe underlying structure to form patterned hardmask 414′ and to disjointhe ones of the second epitaxial source or drain structures 410 and thecorresponding merged ones of the first epitaxial source or drainstructures 412. In an embodiment, the merged region 413 is removed todisjoin the ones of the second epitaxial source or drain structures 410and the corresponding ones of the first epitaxial source or drainstructures 412, forming disjoined second epitaxial source or drainstructures 410′ and first epitaxial source or drain structures 412′. Inone embodiment, the merged region 413 is removed to disjoin the ones ofthe second epitaxial source or drain structures 410 and thecorresponding ones of the first epitaxial source or drain structures 412by anisotropically etching the merged region 413. The patternedphotoresist layer 424 may then be removed.

Referring to FIG. 4D, a dielectric material 430 is formed over thestructure of FIG. 4C. Referring to FIG. 4E, the dielectric material 430is planarized (which may involve removal of layer 422) to form anintervening dielectric structure 432 between the ones of the disjoinedsecond epitaxial source or drain structures 410′ and the correspondingones of the first epitaxial source or drain structures 412′. Thepatterned hardmask 414′ may subsequently be removed to enable contactformation.

Referring again to FIG. 4E, in accordance with an embodiment of thepresent disclosure, an integrated circuit structure 450 includes a firstvertical arrangement of nanowires 406 and a second vertical arrangementof nanowires 404 above a substrate 402. The nanowires of the secondvertical arrangement of nanowires 404 have a horizontal width greaterthan a horizontal width of the nanowires of the first verticalarrangement of nanowires 406. First epitaxial source or drain structures412′ are at ends of the first vertical arrangement of nanowires 406.Second epitaxial source or drain structures 410′ are at ends of thesecond vertical arrangement of nanowires 404. An intervening dielectricstructure 432 is between neighboring ones of the first epitaxial sourceor drain structures 412′ and of the second epitaxial source or drainstructures 410′.

In an embodiment, first epitaxial source or drain structures 412′ andsecond epitaxial source or drain structures 410′ are asymmetrical in thehorizontal direction in the perspective taken in FIG. 4E, as isdepicted, e.g., as a result of separating a merged structure. Referringagain to FIG. 4E, in accordance with an embodiment of the presentdisclosure, a bottom portion of the first epitaxial source or drainstructures 412′ is tapered, and a bottom portion of the second epitaxialsource or drain structures 410′ is tapered. In an embodiment, theuppermost surface of the first epitaxial source or drain structures 412′is a first vertex, and the uppermost surface of the second epitaxialsource or drain structures 410′ is a second vertex, as is depicted. Inan embodiment, the first and second epitaxial source or drain structuresare vertically non-discrete first and second epitaxial source or drainstructures, as depicted in FIG. 4E, and as described in greater detailbelow. In another embodiment, the first and second epitaxial source ordrain structures are vertically discrete first and second epitaxialsource or drain structures, as is also described in greater detailbelow.

Although not depicted in the view of FIG. 4E, but as exemplified inother embodiments described herein, a first gate stack is over the firstvertical arrangement of nanowires, and a second gate stack is over thesecond vertical arrangement of nanowires. In a particular embodiment, afirst gate structure is over a first nanowire or nanowire stack and acorresponding first fin along a first direction. The first gatestructure has a longest dimension along a second direction, the seconddirection orthogonal to the first direction. A second gate structure isover a second nanowire or nanowire stack and over a corresponding secondfin. The second gate structure has a longest dimension along the seconddirection. In one embodiment, the second gate structure is continuouswith the first gate structure along the second direction, e.g., a SAGEwall does not separate the first and second gate structures.

To highlight an exemplary integrated circuit structure having threevertically arranged nanowires, FIG. 5A illustrates a three-dimensionalcross-sectional view of a nanowire-based integrated circuit structure,in accordance with an embodiment of the present disclosure. FIG. 5Billustrates a cross-sectional source or drain view of the nanowire-basedintegrated circuit structure of FIG. 5A, as taken along the a-a′ axis.FIG. 5C illustrates a cross-sectional channel view of the nanowire-basedintegrated circuit structure of FIG. 5A, as taken along the b-b′ axis.

Referring to FIG. 5A, an integrated circuit structure 500 includes oneor more vertically stacked nanowires (504 set) above a substrate 502. Anoptional fin between the bottommost nanowire and the substrate 502 isnot depicted for the sake of emphasizing the nanowire portion forillustrative purposes. Embodiments herein are targeted at both singlewire devices and multiple wire devices. As an example, a threenanowire-based devices having nanowires 504A, 504B and 504C is shown forillustrative purposes. For convenience of description, nanowire 504A isused as an example where description is focused on one of the nanowires.It is to be appreciated that where attributes of one nanowire aredescribed, embodiments based on a plurality of nanowires may have thesame or essentially the same attributes for each of the nanowires.

Each of the nanowires 504 includes a channel region 506 in the nanowire.The channel region 506 has a length (L). Referring to FIG. 5C, thechannel region also has a perimeter (Pc) orthogonal to the length (L).Referring to both FIGS. 5A and 5C, a gate electrode stack 508 surroundsthe entire perimeter (Pc) of each of the channel regions 506. The gateelectrode stack 508 includes a gate electrode along with a gatedielectric layer between the channel region 506 and the gate electrode(not shown). In an embodiment, the channel region is discrete in that itis completely surrounded by the gate electrode stack 508 without anyintervening material such as underlying substrate material or overlyingchannel fabrication materials. Accordingly, in embodiments having aplurality of nanowires 504, the channel regions 506 of the nanowires arealso discrete relative to one another.

Referring to both FIGS. 5A and 5B, integrated circuit structure 500includes a pair of non-discrete source or drain regions 510/512. Thepair of non-discrete source or drain regions 510/512 is on either sideof the channel regions 506 of the plurality of vertically stackednanowires 504. Furthermore, the pair of non-discrete source or drainregions 510/512 is adjoining for the channel regions 506 of theplurality of vertically stacked nanowires 504. In one such embodiment,not depicted, the pair of non-discrete source or drain regions 510/512is directly vertically adjoining for the channel regions 506 in thatepitaxial growth is on and between nanowire portions extending beyondthe channel regions 506 (as exemplified in FIGS. 3C and 4E), wherenanowire ends are shown within the source or drain structures. Inanother embodiment, as depicted in FIG. 5A, the pair of non-discretesource or drain regions 510/512 is indirectly vertically adjoining forthe channel regions 506 in that they are formed at the ends of thenanowires and not between the nanowires.

In an embodiment, as depicted, the source or drain regions 510/512 arenon-discrete in that there are not individual and discrete source ordrain regions for each channel region 506 of a nanowire 504.Accordingly, in embodiments having a plurality of nanowires 504, thesource or drain regions 510/512 of the nanowires are global or unifiedsource or drain regions as opposed to discrete for each nanowire. In oneembodiment, from a cross-sectional perspective orthogonal to the lengthof the discrete channel regions 506, each of the pair of non-discretesource or drain regions 510/512 is approximately rectangular in shapewith a bottom tapered portion and a top vertex portion, as depicted inFIG. 5B. In other embodiments, however, the source or drain regions510/512 of the nanowires are relatively larger yet discretenon-vertically merged epitaxial structures.

In accordance with an embodiment of the present disclosure, and asdepicted in FIGS. 5A and 5B, integrated circuit structure 500 furtherincludes a pair of contacts 514, each contact 514 on one of the pair ofnon-discrete source or drain regions 510/512. In one such embodiment, ina vertical sense, each contact 514 completely surrounds the respectivenon-discrete source or drain region 510/512. In another aspect, theentire perimeter of the non-discrete source or drain regions 510/512 maynot be accessible for contact with contacts 514, and the contact 514thus only partially surrounds the non-discrete source or drain regions510/512, as depicted in FIG. 5B. In a contrasting embodiment, notdepicted, the entire perimeter of the non-discrete source or drainregions 510/512, as taken along the a-a′ axis, is surrounded by thecontacts 514.

Referring to FIGS. 5B and 5C, the non-discrete source or drain regions510/512 are global in the sense that a single unified feature is used asa source or drain region for a plurality (in this case, 3) of nanowires504 and, more particularly, for more than one discrete channel region506. In an embodiment, the pair of non-discrete source or drain regions510/512 is composed of a semiconductor material different than thesemiconductor material of the discrete channel regions 506, e.g., thepair of non-discrete source or drain regions 510/512 is composed of asilicon germanium while the discrete channel regions 506 are composed ofsilicon. In another embodiment, the pair of non-discrete source or drainregions 510/512 is composed of a semiconductor material the same oressentially the same as the semiconductor material of the discretechannel regions 506, e.g., both the pair of non-discrete source or drainregions 510/512 and the discrete channel regions 506 are composed ofsilicon.

Referring again to FIG. 5A, in an embodiment, integrated circuitstructure 500 further includes a pair of spacers 516. As is depicted,outer portions of the pair of spacers 516 may overlap portions of thenon-discrete source or drain regions 510/512, providing for “embedded”portions of the non-discrete source or drain regions 510/512 beneath thepair of spacers 516. As is also depicted, the embedded portions of thenon-discrete source or drain regions 510/512 may not extend beneath theentirety of the pair of spacers 516.

Substrate 502 may be composed of a material suitable for integratedcircuit structure fabrication. In one embodiment, substrate 502 includesa lower bulk substrate composed of a single crystal of a material whichmay include, but is not limited to, silicon, germanium,silicon-germanium or a III-V compound semiconductor material. An upperinsulator layer composed of a material which may include, but is notlimited to, silicon dioxide, silicon nitride or silicon oxy-nitride ison the lower bulk substrate. Thus, the structure 500 may be fabricatedfrom a starting semiconductor-on-insulator substrate. Alternatively, thestructure 500 is formed directly from a bulk substrate and localoxidation is used to form electrically insulative portions in place ofthe above described upper insulator layer. In another alternativeembodiment, the structure 500 is formed directly from a bulk substrateand doping is used to form electrically isolated active regions, such asnanowires, thereon. In one such embodiment, the first nanowire (i.e.,proximate the substrate) is in the form of an omega-FET type structure.

In an embodiment, the nanowires 504 may be sized as wires or ribbons, asdescribed below, and may have squared-off or rounder corners. In anembodiment, the nanowires 504 are composed of a material such as, butnot limited to, silicon, germanium, or a combination thereof. In onesuch embodiment, the nanowires are single-crystalline. For example, fora silicon nanowire 504, a single-crystalline nanowire may be based froma (100) global orientation, e.g., with a <100> plane in the z-direction.As described below, other orientations may also be considered. In anembodiment, the dimensions of the nanowires 504, from a cross-sectionalperspective, are on the nano-scale. For example, in a specificembodiment, the smallest dimension of the nanowires 504 is less thanapproximately 20 nanometers. In an embodiment, the nanowires 504 arecomposed of a strained material, particularly in the channel regions506.

Referring to FIG. 5C, in an embodiment, each of the channel regions 506has a width (Wc) and a height (Hc), the width (Wc) approximately thesame as the height (Hc). That is, in both cases, the channel regions 506are square-like or, if corner-rounded, circle-like in cross-sectionprofile. In another aspect, the width and height of the channel regionneed not be the same, such as the case for nanoribbbons as describedthroughout.

In another aspect, methods of fabricating a nanowire portion of afin/nanowire integrated circuit structure are provided. For example,FIGS. 6A-6E illustrate three-dimensional cross-sectional viewsrepresenting various operations in a method of fabricating a nanowireportion of a fin/nanowire structure, in accordance with an embodiment ofthe present disclosure. It is to be appreciated that, for clarity, alaterally neighboring integrated circuit structure and an interveningdielectric structure implemented between disjoined neighboring source ordrain regions are not depicted in association with FIGS. 6A-6E.

A method of fabricating a nanowire integrated circuit structure mayinclude forming a nanowire above a substrate. In a specific exampleshowing the formation of two silicon nanowires, FIG. 6A illustrates asubstrate 602 (e.g., composed of a bulk substrate silicon substrate 602Awith an insulating silicon dioxide layer 602B there on) having a siliconlayer 604/silicon germanium layer 606/silicon layer 608 stack thereon.It is to be understood that, in another embodiment, a silicon germaniumlayer/silicon layer/silicon germanium layer stack may be used toultimately form two silicon germanium nanowires.

Referring to FIG. 6B, a portion of the silicon layer 604/silicongermanium layer 606/silicon layer 608 stack as well as a top portion ofthe silicon dioxide layer 602B is patterned into a fin-type structure610, e.g., with a mask and plasma etch process. It is to be appreciatedthat, for illustrative purposes, the etch for FIG. 6B is shown asforming two silicon nanowire precursor portions. Although the etch isshown for ease of illustration as ending within a bottom isolationlayer, more complex stacks are contemplated within the context ofembodiments of the present disclosure. For example, the process may beapplied to a nanowire/fin stack as described in association with FIG. 5.

The method may also include forming a channel region in the nanowire,the channel region having a length and a perimeter orthogonal to thelength. In a specific example showing the formation of three gatestructures over the two silicon nanowires, FIG. 6C illustrates thefin-type structure 610 with three sacrificial gates 612A, 612B, and 612Cthereon. In one such embodiment, the three sacrificial gates 612A, 612B,and 612C are composed of a sacrificial gate oxide layer 614 and asacrificial polysilicon gate layer 616 which are blanket deposited andpatterned with a plasma etch process.

Following patterning to form the three sacrificial gates 612A, 612B, and612C, spacers may be formed on the sidewalls of the three sacrificialgates 612A, 612B, and 612C, doping may be performed (e.g., tip and/orsource and drain type doping), and an interlayer dielectric layer may beformed to cover the three sacrificial gates 612A, 612B, and 612C. Theinterlayer dielectric layer may be polished to expose the threesacrificial gates 612A, 612B, and 612C for a replacement gate, orgate-last, process. Referring to FIG. 6D, the three sacrificial gates612A, 612B, and 612C have been removed, leaving spacers 618 and aportion of the interlayer dielectric layer 620 remaining.

Additionally, referring again to FIG. 6D the portions of the silicongermanium layer 606 and the portion of the insulating silicon dioxidelayer 602B of the fin structure 610 are removed in the regionsoriginally covered by the three sacrificial gates 612A, 612B, and 612C.Discrete portions of the silicon layers 604 and 608 thus remain, asdepicted in FIG. 6D.

The discrete portions of the silicon layers 604 and 608 shown in FIG. 6Dwill, in one embodiment, ultimately become channel regions in ananowire-based device. Thus, at the process stage depicted in FIG. 6D,channel engineering or tuning may be performed. For example, in oneembodiment, the discrete portions of the silicon layers 604 and 608shown in FIG. 6D are thinned using oxidation and etch processes. Such anetch process may be performed at the same time the wires are separatedby etching the silicon germanium layer 606. Accordingly, the initialwires formed from silicon layers 604 and 608 begin thicker and arethinned to a size suitable for a channel region in a nanowire device,independent from the sizing of the source and drain regions of thedevice. Thus, in an embodiment, forming the channel region includesremoving a portion of the nanowire, and the resulting perimeters of thesource and drain regions (described below) are greater than theperimeter of the resulting channel region.

The method may also include forming a gate electrode stack surroundingthe entire perimeter of the channel region. In the specific exampleshowing the formation of three gate structures over the two siliconnanowires, FIG. 6E illustrates the structure following deposition of agate dielectric layer 622 (such as a high-k gate dielectric layer) and agate electrode layer 624 (such as a metal gate electrode layer), andsubsequent polishing, in between the spacers 618. That is, gatestructures are formed in the trenches 621 of FIG. 6D. Additionally, FIG.6E depicts the result of the subsequent removal of the interlayerdielectric layer 620 after formation of the permanent gate stack. Theportions of the silicon germanium layer 606 and the portion of theinsulating silicon dioxide layer 602B of the fin structure 610 are alsoremoved in the regions originally covered by the portion of theinterlayer dielectric layer 620 depicted in FIG. 6D. Discrete portionsof the silicon layers 604 and 608 thus remain, as depicted in FIG. 6E.

The method may also include forming a pair of source and drain regionsin the nanowire, on either side of the channel region, each of thesource and drain regions having a perimeter orthogonal to the length ofthe channel region. Specifically, the discrete portions of the siliconlayers 604 and 608 shown in FIG. 6E will, in one embodiment, ultimatelybecome at least a portion of the source and drain regions in ananowire-based device. In one such embodiment, epitaxial source or drainstructures are formed by merging epitaxial material around existingnanowires 604 and 608. In another embodiment, epitaxial source or drainstructures are embedded, e.g., portions of nanowires 604 and 608 areremoved and then source or drain (S/D) growth is performed. In eithercase, in accordance with an embodiment of the present disclosure, suchepitaxial source or drain structures are disjoined from correspondingepitaxial source or drain structures from a neighboring device, asexemplified in association with FIGS. 4A-4E.

The method may subsequently include forming a pair of contacts, a firstof the pair of contacts completely or nearly completely surrounding theperimeter of the source region, and a second of the pair of contactscompletely or nearly completely surrounding the perimeter of the drainregion. Specifically, contacts are formed in the trenches 625 of FIG. 6Efollowing epitaxial growth and recess. In an embodiment, the contactsare formed from a metallic species. In one such embodiment, the metallicspecies is formed by conformally depositing a contact metal and thenfilling any remaining trench volume. The conformal aspect of thedeposition may be performed by using chemical vapor deposition (CVD),atomic layer deposition (ALD), or metal reflow.

In an embodiment, as described throughout, an integrated circuitstructure includes non-planar devices such as, but not limited to, afinFET or a tri-gate device with corresponding one or more overlyingnanowire structures. In such an embodiment, a correspondingsemiconducting channel region is composed of or is formed in athree-dimensional body with one or more discrete nanowire channelportions overlying the three-dimensional body. In one such embodiment,the gate structures surround at least a top surface and a pair ofsidewalls of the three-dimensional body, and further surrounds each ofthe one or more discrete nanowire channel portions.

In an embodiment, as described throughout, a substrate may be composedof a semiconductor material that can withstand a manufacturing processand in which charge can migrate. In an embodiment, the substrate is abulk substrate composed of a crystalline silicon, silicon/germanium orgermanium layer doped with a charge carrier, such as but not limited tophosphorus, arsenic, boron or a combination thereof, to form an activeregion. In one embodiment, the concentration of silicon atoms in a bulksubstrate is greater than 97%. In another embodiment, a bulk substrateis composed of an epitaxial layer grown atop a distinct crystallinesubstrate, e.g. a silicon epitaxial layer grown atop a boron-doped bulksilicon mono-crystalline substrate. A bulk substrate may alternativelybe composed of a group III-V material. In an embodiment, a bulksubstrate is composed of a III-V material such as, but not limited to,gallium nitride, gallium phosphide, gallium arsenide, indium phosphide,indium antimonide, indium gallium arsenide, aluminum gallium arsenide,indium gallium phosphide, or a combination thereof. In one embodiment, abulk substrate is composed of a III-V material and the charge-carrierdopant impurity atoms are ones such as, but not limited to, carbon,silicon, germanium, oxygen, sulfur, selenium or tellurium.

In an embodiment, as described throughout, a trench isolation layer maybe composed of a material suitable to ultimately electrically isolate,or contribute to the isolation of, portions of a permanent gatestructure from an underlying bulk substrate or isolate active regionsformed within an underlying bulk substrate, such as isolating fin activeregions. For example, in one embodiment, a trench isolation layer iscomposed of a dielectric material such as, but not limited to, silicondioxide, silicon oxy-nitride, silicon nitride, or carbon-doped siliconnitride.

In an embodiment, as described throughout, self-aligned gate endcapisolation structures may be composed of a material or materials suitableto ultimately electrically isolate, or contribute to the isolation of,portions of permanent gate structures from one another. Exemplarymaterials or material combinations include a single material structuresuch as silicon dioxide, silicon oxy-nitride, silicon nitride, orcarbon-doped silicon nitride. Other exemplary materials or materialcombinations include a multi-layer stack having lower portion silicondioxide, silicon oxy-nitride, silicon nitride, or carbon-doped siliconnitride and an upper portion higher dielectric constant material such ashafnium oxide.

In an embodiment, as described throughout, gate structures may becomposed of a gate electrode stack which includes a gate dielectriclayer and a gate electrode layer. In an embodiment, the gate electrodeof the gate electrode stack is composed of a metal gate and the gatedielectric layer includes a high-K material.

In an embodiment, the gate dielectric of region is composed of amaterial such as, but not limited to, hafnium oxide, hafniumoxy-nitride, hafnium silicate, lanthanum oxide, zirconium oxide,zirconium silicate, tantalum oxide, barium strontium titanate, bariumtitanate, strontium titanate, yttrium oxide, aluminum oxide, leadscandium tantalum oxide, lead zinc niobate, or a combination thereof.Furthermore, a portion of gate dielectric layer may include a layer ofnative oxide formed from the top few layers of a correspondingsubstrate. In an embodiment, the gate dielectric layer is composed of atop high-k portion and a lower portion composed of an oxide of asemiconductor material. In one embodiment, the gate dielectric layer iscomposed of a top portion of hafnium oxide and a bottom portion ofsilicon dioxide or silicon oxy-nitride. In an embodiment, the top high-kportion consists of a “U”-shaped structure that includes a bottomportion substantially parallel to the surface of the substrate and twosidewall portions that are substantially perpendicular to the topsurface of the substrate. In an embodiment, a gate dielectric of regionincludes a layer of non-native silicon oxide in addition to a layer ofhigh-k material. The layer of non-native silicon oxide may be formedusing a CVD process and may be formed below or above the layer of high-kmaterial. In an exemplary embodiment, a layer of non-native siliconoxide is formed beneath a layer of high-k material.

In an embodiment, a gate electrode is composed of a metal layer such as,but not limited to, metal nitrides, metal carbides, metal silicides,metal aluminides, hafnium, zirconium, titanium, tantalum, aluminum,ruthenium, palladium, platinum, cobalt, nickel or conductive metaloxides. In a specific embodiment, the gate electrode is composed of anon-workfunction-setting fill material formed above a metalworkfunction-setting layer. In some implementations, the gate electrodemay consist of a “U”-shaped structure that includes a bottom portionsubstantially parallel to the surface of the substrate and two sidewallportions that are substantially perpendicular to the top surface of thesubstrate. In another implementation, at least one of the metal layersthat form the gate electrode may simply be a planar layer that issubstantially parallel to the top surface of the substrate and does notinclude sidewall portions substantially perpendicular to the top surfaceof the substrate. In further implementations of the disclosure, the gateelectrode may consist of a combination of U-shaped structures andplanar, non-U-shaped structures. For example, the gate electrode mayconsist of one or more U-shaped metal layers formed atop one or moreplanar, non-U-shaped layers.

Spacers associated with the gate electrode stacks may be composed of amaterial suitable to ultimately electrically isolate, or contribute tothe isolation of, a permanent gate structure from adjacent conductivecontacts, such as self-aligned contacts. For example, in one embodiment,the spacers are composed of a dielectric material such as, but notlimited to, silicon dioxide, silicon oxy-nitride, silicon nitride, orcarbon-doped silicon nitride.

In an embodiment, as described throughout, local interconnects, gatecontacts, overlying gate contact vias, and overlying metal interconnectsmay be composed of a conductive material. In an embodiment, one or moreof the contacts or vias are composed of a metal species. The metalspecies may be a pure metal, such as tungsten, nickel, or cobalt, or maybe an alloy such as a metal-metal alloy or a metal-semiconductor alloy(e.g., such as a silicide material). A common example is the use ofcopper structures that may or may not include barrier layers (such as Taor TaN layers) between the copper and surrounding ILD material. As usedherein, the term metal includes alloys, stacks, and other combinationsof multiple metals. For example, the metal interconnect lines mayinclude barrier layers, stacks of different metals or alloys, etc.

In an embodiment (although not shown), a contact pattern which isessentially perfectly aligned to an existing gate pattern is formedwhile eliminating the use of a lithographic step with exceedingly tightregistration budget. In one such embodiment, this approach enables theuse of intrinsically highly selective wet etching (e.g., versusconventionally implemented dry or plasma etching) to generate contactopenings. In an embodiment, a contact pattern is formed by utilizing anexisting gate pattern in combination with a contact plug lithographyoperation. In one such embodiment, the approach enables elimination ofthe need for an otherwise critical lithography operation to generate acontact pattern, as used in conventional approaches. In an embodiment, atrench contact grid is not separately patterned, but is rather formedbetween poly (gate) lines. For example, in one such embodiment, a trenchcontact grid is formed subsequent to gate grating patterning but priorto gate grating cuts.

Furthermore, gate structures described herein may be fabricated by areplacement gate process. In such a scheme, dummy gate material such aspolysilicon or silicon nitride pillar material, may be removed andreplaced with permanent gate electrode material. In one such embodiment,a permanent gate dielectric layer is also formed in this process, asopposed to being carried through from earlier processing. In anembodiment, dummy gates are removed by a dry etch or wet etch process.In one embodiment, dummy gates are composed of polycrystalline siliconor amorphous silicon and are removed with a dry etch process includinguse of SF₆. In another embodiment, dummy gates are composed ofpolycrystalline silicon or amorphous silicon and are removed with a wetetch process including use of aqueous NH₄OH or tetramethylammoniumhydroxide. In one embodiment, dummy gates are composed of siliconnitride and are removed with a wet etch including aqueous phosphoricacid.

In an embodiment, one or more approaches described herein contemplateessentially a dummy and replacement gate process in combination with adummy and replacement contact process to fabricate an integrated circuitstructure. In one such embodiment, the replacement contact process isperformed after the replacement gate process to allow high temperatureanneal of at least a portion of the permanent gate stack. For example,in a specific such embodiment, an anneal of at least a portion of thepermanent gate structures, e.g., after a gate dielectric layer isformed, is performed at a temperature greater than approximately 600degrees Celsius. The anneal is performed prior to formation of thepermanent contacts.

In an embodiment, an integrated circuit structure has contact structuresthat contact portions of a gate electrode formed over an active region.In general, prior to (e.g., in addition to) forming a gate contactstructure (such as a via) over an active portion of a gate and in a samelayer as a trench contact via, one or more embodiments of the presentdisclosure include first using a gate aligned trench contact process.Such a process may be implemented to form trench contact structures forintegrated circuit structure or semiconductor structure fabrication,e.g., for integrated circuit fabrication. In an embodiment, a trenchcontact pattern is formed as aligned to an existing gate pattern. Bycontrast, conventional approaches typically involve an additionallithography process with tight registration of a lithographic contactpattern to an existing gate pattern in combination with selectivecontact etches. For example, a conventional process may includepatterning of a poly (gate) grid with separate patterning of contactfeatures.

In an embodiment, as used throughout the present description, interlayerdielectric (ILD) material is composed of or includes a layer of adielectric or insulating material. Examples of suitable dielectricmaterials include, but are not limited to, oxides of silicon (e.g.,silicon dioxide (SiO₂)), doped oxides of silicon, fluorinated oxides ofsilicon, carbon doped oxides of silicon, various low-k dielectricmaterials known in the arts, and combinations thereof. The interlayerdielectric material may be formed by conventional techniques, such as,for example, chemical vapor deposition (CVD), physical vapor deposition(PVD), or by other deposition methods.

In an embodiment, as is also used throughout the present description,metal lines or interconnect line material (and via material) is composedof one or more metal or other conductive structures. A common example isthe use of copper lines and structures that may or may not includebarrier layers between the copper and surrounding ILD material. As usedherein, the term metal includes alloys, stacks, and other combinationsof multiple metals. For example, the metal interconnect lines mayinclude barrier layers (e.g., layers including one or more of Ta, TaN,Ti or TiN), stacks of different metals or alloys, etc. Thus, theinterconnect lines may be a single material layer, or may be formed fromseveral layers, including conductive liner layers and fill layers. Anysuitable deposition process, such as electroplating, chemical vapordeposition or physical vapor deposition, may be used to forminterconnect lines. In an embodiment, the interconnect lines arecomposed of a conductive material such as, but not limited to, Cu, Al,Ti, Zr, Hf, V, Ru, Co, Ni, Pd, Pt, W, Ag, Au or alloys thereof. Theinterconnect lines are also sometimes referred to in the art as traces,wires, lines, metal, or simply interconnect.

In an embodiment, as is also used throughout the present description,hardmask materials, capping layers, or plugs are composed of dielectricmaterials different from the interlayer dielectric material. In oneembodiment, different hardmask, capping or plug materials may be used indifferent regions so as to provide different growth or etch selectivityto each other and to the underlying dielectric and metal layers. In someembodiments, a hardmask layer, capping or plug layer includes a layer ofa nitride of silicon (e.g., silicon nitride) or a layer of an oxide ofsilicon, or both, or a combination thereof. Other suitable materials mayinclude carbon-based materials. Other hardmask, capping or plug layersknown in the arts may be used depending upon the particularimplementation. The hardmask, capping or plug layers maybe formed byCVD, PVD, or by other deposition methods.

In an embodiment, as is also used throughout the present description,lithographic operations are performed using 193 nm immersion litho(i193), EUV and/or EBDW lithography, or the like. A positive tone or anegative tone resist may be used. In one embodiment, a lithographic maskis a trilayer mask composed of a topographic masking portion, ananti-reflective coating (ARC) layer, and a photoresist layer. In aparticular such embodiment, the topographic masking portion is a carbonhardmask (CHM) layer and the anti-reflective coating layer is a siliconARC layer.

Embodiments disclosed herein may be used to manufacture a wide varietyof different types of integrated circuits and/or microelectronicdevices. Examples of such integrated circuits include, but are notlimited to, processors, chipset components, graphics processors, digitalsignal processors, micro-controllers, and the like. In otherembodiments, semiconductor memory may be manufactured. Moreover, theintegrated circuits or other microelectronic devices may be used in awide variety of electronic devices known in the arts. For example, incomputer systems (e.g., desktop, laptop, server), cellular phones,personal electronics, etc. The integrated circuits may be coupled with abus and other components in the systems. For example, a processor may becoupled by one or more buses to a memory, a chipset, etc. Each of theprocessor, the memory, and the chipset, may potentially be manufacturedusing the approaches disclosed herein.

FIG. 7 illustrates a computing device 700 in accordance with oneimplementation of an embodiment of the present disclosure. The computingdevice 700 houses a board 702. The board 702 may include a number ofcomponents, including but not limited to a processor 704 and at leastone communication chip 706. The processor 704 is physically andelectrically coupled to the board 702. In some implementations the atleast one communication chip 706 is also physically and electricallycoupled to the board 702. In further implementations, the communicationchip 706 is part of the processor 704.

Depending on its applications, computing device 700 may include othercomponents that may or may not be physically and electrically coupled tothe board 702. These other components include, but are not limited to,volatile memory (e.g., DRAM), non-volatile memory (e.g., ROM), flashmemory, a graphics processor, a digital signal processor, a cryptoprocessor, a chipset, an antenna, a display, a touchscreen display, atouchscreen controller, a battery, an audio codec, a video codec, apower amplifier, a global positioning system (GPS) device, a compass, anaccelerometer, a gyroscope, a speaker, a camera, and a mass storagedevice (such as hard disk drive, compact disk (CD), digital versatiledisk (DVD), and so forth).

The communication chip 706 enables wireless communications for thetransfer of data to and from the computing device 700. The term“wireless” and its derivatives may be used to describe circuits,devices, systems, methods, techniques, communications channels, etc.,that may communicate data through the use of modulated electromagneticradiation through a non-solid medium. The term does not imply that theassociated devices do not contain any wires, although in someembodiments they might not. The communication chip 706 may implement anyof a number of wireless standards or protocols, including but notlimited to Wi-Fi (IEEE 802.11 family), WiMAX (IEEE 802.16 family), IEEE802.20, long term evolution (LTE), Ev-DO, HSPA+, HSDPA+, HSUPA+, EDGE,GSM, GPRS, CDMA, TDMA, DECT, Bluetooth, derivatives thereof, as well asany other wireless protocols that are designated as 3G, 4G, 5G, andbeyond. The computing device 700 may include a plurality ofcommunication chips 706. For instance, a first communication chip 706may be dedicated to shorter range wireless communications such as Wi-Fiand Bluetooth and a second communication chip 706 may be dedicated tolonger range wireless communications such as GPS, EDGE, GPRS, CDMA,WiMAX, LTE, Ev-DO, and others.

The processor 704 of the computing device 700 includes an integratedcircuit die packaged within the processor 704. The integrated circuitdie of the processor 704 may include one or more structures, such asintegrated circuit structures built in accordance with implementationsof embodiments of the present disclosure. The term “processor” may referto any device or portion of a device that processes electronic data fromregisters and/or memory to transform that electronic data into otherelectronic data that may be stored in registers and/or memory.

The communication chip 706 also includes an integrated circuit diepackaged within the communication chip 706. The integrated circuit dieof the communication chip 706 may include one or more structures, suchas integrated circuit structures built in accordance withimplementations of embodiments of the present disclosure.

In further implementations, another component housed within thecomputing device 700 may contain an integrated circuit die that includesone or structures, such as integrated circuit structures built inaccordance with implementations of embodiments of the presentdisclosure.

In various implementations, the computing device 700 may be a laptop, anetbook, a notebook, an ultrabook, a smartphone, a tablet, a personaldigital assistant (PDA), an ultra mobile PC, a mobile phone, a desktopcomputer, a server, a printer, a scanner, a monitor, a set-top box, anentertainment control unit, a digital camera, a portable music player,or a digital video recorder. In further implementations, the computingdevice 700 may be any other electronic device that processes data.

FIG. 8 illustrates an interposer 800 that includes one or moreembodiments of the present disclosure. The interposer 800 is anintervening substrate used to bridge a first substrate 802 to a secondsubstrate 804. The first substrate 802 may be, for instance, anintegrated circuit die. The second substrate 804 may be, for instance, amemory module, a computer motherboard, or another integrated circuitdie. Generally, the purpose of an interposer 800 is to spread aconnection to a wider pitch or to reroute a connection to a differentconnection. For example, an interposer 800 may couple an integratedcircuit die to a ball grid array (BGA) 806 that can subsequently becoupled to the second substrate 804. In some embodiments, the first andsecond substrates 802/804 are attached to opposing sides of theinterposer 800. In other embodiments, the first and second substrates802/804 are attached to the same side of the interposer 800. And infurther embodiments, three or more substrates are interconnected by wayof the interposer 800.

The interposer 800 may be formed of an epoxy resin, afiberglass-reinforced epoxy resin, a ceramic material, or a polymermaterial such as polyimide. In further implementations, the interposermay be formed of alternate rigid or flexible materials that may includethe same materials described above for use in a semiconductor substrate,such as silicon, germanium, and other group III-V and group IVmaterials.

The interposer may include metal interconnects 808 and vias 810,including but not limited to through-silicon vias (TSVs) 812. Theinterposer 800 may further include embedded devices 814, including bothpassive and active devices. Such devices include, but are not limitedto, capacitors, decoupling capacitors, resistors, inductors, fuses,diodes, transformers, sensors, and electrostatic discharge (ESD)devices. More complex devices such as radio-frequency (RF) devices,power amplifiers, power management devices, antennas, arrays, sensors,and MEMS devices may also be formed on the interposer 800. In accordancewith embodiments of the disclosure, apparatuses or processes disclosedherein may be used in the fabrication of interposer 800 or in thefabrication of components included in the interposer 800.

Thus, embodiments of the present disclosure include neighboringgate-all-around integrated circuit structures having disjoined epitaxialsource or drain regions, and methods of fabricating neighboringgate-all-around integrated circuit structures having disjoined epitaxialsource or drain regions.

The above description of illustrated implementations of embodiments ofthe disclosure, including what is described in the Abstract, is notintended to be exhaustive or to limit the disclosure to the preciseforms disclosed. While specific implementations of, and examples for,the disclosure are described herein for illustrative purposes, variousequivalent modifications are possible within the scope of thedisclosure, as those skilled in the relevant art will recognize.

These modifications may be made to the disclosure in light of the abovedetailed description. The terms used in the following claims should notbe construed to limit the disclosure to the specific implementationsdisclosed in the specification and the claims. Rather, the scope of thedisclosure is to be determined entirely by the following claims, whichare to be construed in accordance with established doctrines of claiminterpretation.

Example Embodiment 1

An integrated circuit structure includes a first vertical arrangement ofnanowires and a second vertical arrangement of nanowires above asubstrate, the nanowires of the second vertical arrangement of nanowireshaving a horizontal width greater than a horizontal width of thenanowires of the first vertical arrangement of nanowires. A first gatestack is over the first vertical arrangement of nanowires. A second gatestack is over the second vertical arrangement of nanowires. Firstepitaxial source or drain structures are at ends of the first verticalarrangement of nanowires. Second epitaxial source or drain structuresare at ends of the second vertical arrangement of nanowires. Anintervening dielectric structure is between neighboring ones of thefirst epitaxial source or drain structures and of the second epitaxialsource or drain structures.

Example Embodiment 2

The integrated circuit structure of example embodiment 1, wherein theuppermost surface of the first epitaxial source or drain structures is afirst vertex, and the uppermost surface of the second epitaxial sourceor drain structures is a second vertex.

Example Embodiment 3

The integrated circuit structure of example embodiment 1 or 2, wherein abottom portion of the first epitaxial source or drain structures istapered, and a bottom portion of the second epitaxial source or drainstructures is tapered.

Example Embodiment 4

The integrated circuit structure of example embodiment 1, 2 or 3,wherein the first gate stack has dielectric sidewall spacers, and thefirst epitaxial source or drain structures are first embedded epitaxialsource or drain structures extending beneath the dielectric sidewallsspacers of the first gate stack, and wherein the second gate stack hasdielectric sidewall spacers, and the second epitaxial source or drainstructures are second embedded epitaxial source or drain structuresextending beneath the dielectric sidewalls spacers of the second gatestack.

Example Embodiment 5

The integrated circuit structure of example embodiment 1, 2, 3 or 4,wherein the first and second epitaxial source or drain structures arenon-discrete first and second epitaxial source or drain structures.

Example Embodiment 6

The integrated circuit structure of example embodiment 1, 2, 3, 4 or 5,wherein the first vertical arrangement of nanowires is over a first fin,and the second vertical arrangement of nanowires is over a second fin.

Example Embodiment 7

The integrated circuit structure of example embodiment 1, 2, 3, 4, 5 or6, wherein the first and second gate stacks each include a high-k gatedielectric layer and a metal gate electrode.

Example Embodiment 8

A method of fabricating an integrated circuit structure includes forminga first vertical arrangement of nanowires and a second verticalarrangement of nanowires above a substrate, the nanowires of the secondvertical arrangement of nanowires having a horizontal width greater thana horizontal width of the nanowires of the first vertical arrangement ofnanowires. First epitaxial source or drain structures are formed at endsof the first vertical arrangement of nanowires, and second epitaxialsource or drain structures are formed at ends of the second verticalarrangement of nanowires. Ones of the second epitaxial source or drainstructures and corresponding ones of the first epitaxial source or drainstructures have a merged region there between. The merged region isremoved to disjoin the ones of the second epitaxial source or drainstructures and the corresponding ones of the first epitaxial source ordrain structures. An intervening dielectric structure is formed betweenthe ones of the second epitaxial source or drain structures and thecorresponding ones of the first epitaxial source or drain structures.

Example Embodiment 9

The method of example embodiment 8, wherein removing the merged regionto disjoin the ones of the second epitaxial source or drain structuresand the corresponding ones of the first epitaxial source or drainstructures involves anisotropically etching the merged region.

Example Embodiment 10

The method of example embodiment 8 or 9, wherein the uppermost surfaceof the first epitaxial source or drain structures is a first vertex, andthe uppermost surface of the second epitaxial source or drain structuresis a second vertex.

Example Embodiment 11

The method of example embodiment 8, 9 or 10, wherein a bottom portion ofthe first epitaxial source or drain structures is tapered, and a bottomportion of the second epitaxial source or drain structures is tapered.

Example Embodiment 12

The method of example embodiment 8, 9, 10 or 11, wherein the first gatestack has dielectric sidewall spacers, and the first epitaxial source ordrain structures are first embedded epitaxial source or drain structuresextending beneath the dielectric sidewalls spacers of the first gatestack, and wherein the second gate stack has dielectric sidewallspacers, and the second epitaxial source or drain structures are secondembedded epitaxial source or drain structures extending beneath thedielectric sidewalls spacers of the second gate stack.

Example Embodiment 13

The method of example embodiment 8, 9, 10, 11 or 12, wherein the firstand second epitaxial source or drain structures are non-discrete firstand second epitaxial source or drain structures.

Example Embodiment 14

The method of example embodiment 8, 9, 10, 11, 12 or 13, wherein thefirst vertical arrangement of nanowires is over a first fin, and thesecond vertical arrangement of nanowires is over a second fin.

Example Embodiment 15

The method of example embodiment 8, 9, 10, 11, 12, 13 or 14, wherein thefirst and second gate stacks each include a high-k gate dielectric layerand a metal gate electrode.

Example Embodiment 16

An integrated circuit structure includes a first fin having a longestdimension along a first direction. A first nanowire is over the firstfin. A second fin having a longest dimension is along the firstdirection. A second nanowire is over the second fin. The second nanowireis wider than the nanowire. A first gate structure is over the firstnanowire and the first fin, the first gate structure having a longestdimension along a second direction, the second direction orthogonal tothe first direction. A second gate structure is over the second nanowireand over the second fin, the second gate structure having a longestdimension along the second direction, the second gate structurecontinuous with the first gate structure along the second direction.First epitaxial source or drain structures are at ends of the firstnanowire. Second epitaxial source or drain structures are at ends of thesecond nanowire. An intervening dielectric structure is betweenneighboring ones of the first epitaxial source or drain structures andof the second epitaxial source or drain structures.

Example Embodiment 17

The integrated circuit structure of example embodiment 16, furtherincluding first dielectric sidewall spacers along the first gatestructure, the first epitaxial source or drain structures extendingbeneath the first dielectric sidewalls spacers, and further includingsecond dielectric sidewall spacers along the second gate structure, thesecond epitaxial source or drain structures extending beneath the seconddielectric sidewalls spacers.

Example Embodiment 18

The integrated circuit structure of example embodiment 16 or 17, whereinthe uppermost surface of the first epitaxial source or drain structuresis a first vertex, and the uppermost surface of the second epitaxialsource or drain structures is a second vertex.

Example Embodiment 19

The integrated circuit structure of example embodiment 16, 17 or 18,wherein a bottom portion of the first epitaxial source or drainstructures is tapered, and a bottom portion of the second epitaxialsource or drain structures is tapered.

Example Embodiment 20

The integrated circuit structure of example embodiment 16, 17, 18 or 19,wherein the first and second epitaxial source or drain structures arenon-discrete first and second epitaxial source or drain structures.

What is claimed is:
 1. An integrated circuit structure, comprising: afirst vertical arrangement of nanowires and a second verticalarrangement of nanowires above a substrate, the nanowires of the secondvertical arrangement of nanowires having a horizontal width greater thana horizontal width of the nanowires of the first vertical arrangement ofnanowires; a first gate stack over the first vertical arrangement ofnanowires; a second gate stack over the second vertical arrangement ofnanowires; first epitaxial source or drain structures at ends of thefirst vertical arrangement of nanowires; second epitaxial source ordrain structures at ends of the second vertical arrangement ofnanowires; and an intervening dielectric structure between neighboringones of the first epitaxial source or drain structures and of the secondepitaxial source or drain structures.
 2. The integrated circuitstructure of claim 1, wherein the uppermost surface of the firstepitaxial source or drain structures is a first vertex, and theuppermost surface of the second epitaxial source or drain structures isa second vertex.
 3. The integrated circuit structure of claim 1, whereina bottom portion of the first epitaxial source or drain structures istapered, and a bottom portion of the second epitaxial source or drainstructures is tapered.
 4. The integrated circuit structure of claim 1,wherein the first gate stack has dielectric sidewall spacers, and thefirst epitaxial source or drain structures are first embedded epitaxialsource or drain structures extending beneath the dielectric sidewallsspacers of the first gate stack, and wherein the second gate stack hasdielectric sidewall spacers, and the second epitaxial source or drainstructures are second embedded epitaxial source or drain structuresextending beneath the dielectric sidewalls spacers of the second gatestack.
 5. The integrated circuit structure of claim 1, wherein the firstand second epitaxial source or drain structures are non-discrete firstand second epitaxial source or drain structures.
 6. The integratedcircuit structure of claim 1, wherein the first vertical arrangement ofnanowires is over a first fin, and the second vertical arrangement ofnanowires is over a second fin.
 7. The integrated circuit structure ofclaim 1, wherein the first and second gate stacks each comprise a high-kgate dielectric layer and a metal gate electrode.
 8. A method offabricating an integrated circuit structure, the method comprising:forming a first vertical arrangement of nanowires and a second verticalarrangement of nanowires above a substrate, the nanowires of the secondvertical arrangement of nanowires having a horizontal width greater thana horizontal width of the nanowires of the first vertical arrangement ofnanowires; forming first epitaxial source or drain structures at ends ofthe first vertical arrangement of nanowires, and forming secondepitaxial source or drain structures at ends of the second verticalarrangement of nanowires, ones of the second epitaxial source or drainstructures and corresponding ones of the first epitaxial source or drainstructures having a merged region there between; removing the mergedregion to disjoin the ones of the second epitaxial source or drainstructures and the corresponding ones of the first epitaxial source ordrain structures; and forming an intervening dielectric structurebetween the ones of the second epitaxial source or drain structures andthe corresponding ones of the first epitaxial source or drainstructures.
 9. The method of claim 8, wherein removing the merged regionto disjoin the ones of the second epitaxial source or drain structuresand the corresponding ones of the first epitaxial source or drainstructures comprises anisotropically etching the merged region.
 10. Themethod of claim 8, wherein the uppermost surface of the first epitaxialsource or drain structures is a first vertex, and the uppermost surfaceof the second epitaxial source or drain structures is a second vertex.11. The method of claim 8, wherein a bottom portion of the firstepitaxial source or drain structures is tapered, and a bottom portion ofthe second epitaxial source or drain structures is tapered.
 12. Themethod of claim 8, wherein the first gate stack has dielectric sidewallspacers, and the first epitaxial source or drain structures are firstembedded epitaxial source or drain structures extending beneath thedielectric sidewalls spacers of the first gate stack, and wherein thesecond gate stack has dielectric sidewall spacers, and the secondepitaxial source or drain structures are second embedded epitaxialsource or drain structures extending beneath the dielectric sidewallsspacers of the second gate stack.
 13. The method of claim 8, wherein thefirst and second epitaxial source or drain structures are non-discretefirst and second epitaxial source or drain structures.
 14. The method ofclaim 8, wherein the first vertical arrangement of nanowires is over afirst fin, and the second vertical arrangement of nanowires is over asecond fin.
 15. The method of claim 8, wherein the first and second gatestacks each comprise a high-k gate dielectric layer and a metal gateelectrode.
 16. An integrated circuit structure, comprising: a first finhaving a longest dimension along a first direction; a first nanowireover the first fin; a second fin having a longest dimension along thefirst direction; a second nanowire over the second fin, wherein thesecond nanowire is wider than the nanowire; a first gate structure overthe first nanowire and the first fin, the first gate structure having alongest dimension along a second direction, the second directionorthogonal to the first direction; a second gate structure over thesecond nanowire and over the second fin, the second gate structurehaving a longest dimension along the second direction, the second gatestructure continuous with the first gate structure along the seconddirection; first epitaxial source or drain structures at ends of thefirst nanowire; second epitaxial source or drain structures at ends ofthe second nanowire; and an intervening dielectric structure betweenneighboring ones of the first epitaxial source or drain structures andof the second epitaxial source or drain structures.
 17. The integratedcircuit structure of claim 16, further comprising: first dielectricsidewall spacers along the first gate structure, the first epitaxialsource or drain structures extending beneath the first dielectricsidewalls spacers; and second dielectric sidewall spacers along thesecond gate structure, the second epitaxial source or drain structuresextending beneath the second dielectric sidewalls spacers.
 18. Theintegrated circuit structure of claim 16, wherein the uppermost surfaceof the first epitaxial source or drain structures is a first vertex, andthe uppermost surface of the second epitaxial source or drain structuresis a second vertex.
 19. The integrated circuit structure of claim 16,wherein a bottom portion of the first epitaxial source or drainstructures is tapered, and a bottom portion of the second epitaxialsource or drain structures is tapered.
 20. The integrated circuitstructure of claim 16, wherein the first and second epitaxial source ordrain structures are non-discrete first and second epitaxial source ordrain structures.